Flexible frame with articulating joints

ABSTRACT

A collapsible frame for supporting a fabric structure includes frame members which themselves can be plastically deformed as well as folded around one or more hinges. The ductile frame members can be deformed plastically to hold the fabric structure in a predetermined orientation. When not in use, the frame can be folded around the hinges disposed between the individual frame members. Folding the frame around the hinges significantly reduces the possibility of the ductile frame members work-hardening and experiencing a metal fatigue failure.

BACKGROUND OF THE INVENTION

This invention relates generally to outdoor equipment and, in particular fabric structures supported by rigid frames

It is well-known in the art to provide outdoor equipment consisting of a lightweight fabric structure supported by a collapsible resilient frame. For example, U.S. Pat. No. 5,163,461 to Ivanovich et al. discloses a self-erecting shelter consisting of a fabric material stretched over an armature made of a highly resilient material, such as spring steel. The shelter can be collapsed by coiling the armature into a flattened package. Because the spring steel armature is highly elastic, the armature does not plastically deform and therefore springs back into shape to form the structure when released.

It is also well-known in the art to provide outdoor equipment consisting of a lightweight fabric structure supported by a hinged, rigid or semi-rigid frame, for example, U.S. Pat. No. 5,842,495 to Egnew et al. discloses a portable shelter consisting of a fabric material stretched over a series of rigid bows that are hinged at a common anchor point so that the bows can be collapsed one on top of the other. The bows are also hinged at a center point so each bow can be folded in half to further reduce the size of the folded assembly. What the prior art lacks, however, and what the present invention provides is a fabric structure that is supported by a collapsible frame in which the frame members themselves can be plastically deformed as well as folded around one or more hinges.

SUMMARY OF THE INVENTION

The present invention comprises a fabric structure that is supported by a collapsible frame in which the frame members themselves can be plastically deformed as well as folded around one or more hinges. According to an illustrative embodiment, the fabric structure comprises a slouch hat with a flexible frame attached to the perimeter of the brim. The ductile frame members can be deformed plastically to hold one side of the brim in a particular orientation when the hat is in use. When not in use, the hat can be folded around the hinges disposed between the individual frame members. Folding the frame around the hinges significantly reduces the possibility of the ductile frame members work-hardening and experiencing a metal fatigue failure.

BRIEF DESCRIPTION OF THE DRAWING

The present invention will be better understood from a reading of the following detailed description, taken in conjunction with the accompanying drawing figures in which like references designate like elements and, in which:

FIG. 1 is a perspective view of a fabric structure supported by a collapsible frame incorporating features of the present invention;

FIG. 2A is a perspective view of an articulating joint incorporating features of the present invention;

FIG. 2B is a perspective view of an articulating joint incorporating features of the present invention;

FIG. 2C is a perspective view of an articulating joint incorporating features of the present invention;

FIG. 3 is a perspective view of the fabric structure of FIG. 1 in a folded configuration; and

FIG. 4 is a perspective view of an alternative embodiment of a fabric structure supported by a collapsible frame incorporating features of the present invention.

DETAILED DESCRIPTION

The drawing figures are intended to illustrate the general manner of construction and are not necessarily to scale. In the detailed description and in the drawing figures, specific illustrative examples are shown and herein described in detail. It should be understood, however, that the drawing figures and detailed description are not intended to limit the invention to the particular form disclosed, but are merely illustrative and intended to teach one of ordinary skill how to make and/or use the invention claimed herein and for setting forth the best mode for carrying out the invention.

With reference to the figures and, in particular FIGS. 1 and 3, a fabric structure, which in the illustrative embodiment comprises a cloth slouch hat 10 having a brim 12, is supported by a flexible frame 14. In the illustrative embodiment, flexible frame 14 consists of four elongated frame members 16A, 16B, 16C, and 16D, which are connected together by four articulating joints 18A, 18B, 18C, and 18D. Flexible frame 14 is attached to brim 12 by means of clips 20 attached directly to elongated frame members 16A, 16B, 16C, and 16D, as well as by clip members 22 which are integral to articulating joints 18A, 18B, 18C, and 18D. Although in the illustrative embodiment flexible frame 14 is attached to brim 12 using clips, other temporary or permanent means, such as clips, pins, clamps or magnets may be utilized without departing from the scope of the invention.

In the illustrative embodiment, elongated frame members 16A, 16B, 16C, and 16D, have a core 28 made of 0.035 inch diameter ductile aluminum alloy such as ER4043, having a yield strength of 10,000 psi and an ultimate tensile strength of 30,000 psi. Although aluminum alloy is used in the illustrative embodiment, any suitable material having a high degree of plasticity such as low carbon steel may be utilized without departing from the scope of the invention. The high degree of plasticity is desirable so that the elongated frame members 16A, 16B, 16C, and 16D, can be deformed such as at bend 24 and at bend 26 and thereafter will substantially retain the shape, for example to hold one side of brim 12 in an upright folded position. In the illustrative embodiment, elongated frame members 16A, 16B, 16C, and 16D further have a flexible sheath 30 comprising 0.160 to 0.180 inch (4.0 to 4.5 mm) diameter hollow core vinyl screen spline. The purpose of the flexible sheath is to increase the effective diameter of four elongated frame members 16A, 16B, 16C, and 16D. thereby making it easier to manipulate the four elongated frame members 16A, 16B, 16C, and 16D by hand. The increased effective diameter also increases the bend radius of bend 24 and bend 26, thereby making it less likely core 28 will work harden with repeated bending and fail from metal fatigue.

Although it would be possible to fold hat 10 relatively flat for storage simply by bending the four elongated frame members 16A, 16B, 16C, and 16D as noted above, such repeated bending would eventually lead to work hardening and metal fatigue failure of elongated frame members 16A, 16B, 16C, and 16D. Accordingly, articulating joints 18A, 18B, 18C, and 18D are provided. With additional reference to FIG. 2, articulating joint 18A is composed of a first clevis portion 32, a second clevis portion 34 and a connecting link 36. First clevis portion 32 is attached (e.g. by adhesive) to an end portion 38 of frame member 16A. Second clevis portion 34 is attached (e.g. by adhesive) to an end portion 40 of frame member 16B. Connecting link 36 is rotatably attached to first clevis portion 32 and second clevis portion 34 about pivot axes 42 and 44. The center distance between axes 42 and 44 is greater than the width of first clevis portion 32 and second clevis portion 34. This enables articulating joint 18A to assume a “Z” shape as shown in FIG. 2B, or to rotate through 180° as shown in FIG. 2C. The structure and operation of articulating joints 18B, 18C, and 18D are substantially the same as articulating joint 18A and therefore will not be discussed in detail herein. As shown in FIG. 3, by appropriate rotation of articulating joints 18A, 18B, 18C, and 18D, the fabric structure 10 can be folded flat without substantial bending of elongated frame members 16A, 16B, 16C, and 16D

According to an alternative embodiment, a fabric structure 110 is supported by a flexible frame 114. In the alternative embodiment, flexible frame 114 consists of four elongated frame members 116A, 116B, 116C, and 116D, which are connected together by four articulating joints 118A, 118B, 118C, and 118D, however, flexible frame 114 is contained within a pocket inside of the brim 112 of fabric structure 110. This obviates the need for clips, pins, clamps magnets or other temporary means of attachment.

Although certain illustrative embodiments and methods have been disclosed herein, it will be apparent from the foregoing disclosure to those skilled in the art that variations and modifications of such embodiments and methods may be made without departing from the invention. For example, although in illustrative embodiment the fabric structure was made of cloth, any flexible material such as leather, rubber or plastic could be used without departing from the invention and therefore as used herein, the word “fabric” is defined to mean any flexible material capable of being supported by a frame. Moreover, although in the illustrative embodiment the fabric structure comprises a slouch hat, other structures including shirt collars, covered hammocks, tents, umbrellas, inflatable boats, vests, face masks, inflatable pool toys, and car sun shades may be supported by a flexible frame incorporating features of the present invention. Accordingly, it is intended that the invention should be limited only to the extent required by the appended claims and the rules and principles of applicable law. Additionally, as used herein, references to direction such as “up” or “down” as well as recited materials or methods of attachment are intended to be exemplary and are not considered as limiting the invention and, unless otherwise specifically defined, the terms “generally,” “substantially,” or “approximately” when used with mathematical concepts or measurements mean within ±10 degrees of angle or within 10 percent of the measurement, whichever is greater. As used herein, a step of “providing” a structural element recited in a method claim means and includes obtaining, fabricating, purchasing, acquiring or otherwise gaining access to the structural element for performing the steps of the method. As used herein, the claim terms are to be given their broadest reasonable meaning unless a clear disavowal of that meaning appears in the record in substantially the following form (“As used herein the term ______ is defined to mean ______”) 

What is claimed is:
 1. A flexible frame (14) for supporting a fabric structure (10), said frame (14) comprising: a plurality of elongated frame members (16A, 16B, 16C, 16D), each of said plurality of elongated frame members (16) having a first end (38) and second end (40); and a plurality of articulating joints (18A, 18B, 18C, 18D), each of said plurality of articulating joins (18A, 18B, 18C, 18D) comprising a hinge (42, 44) that rotates from an inline position to a rotated position in which the hinge (42, 44) is rotated 180° from the inline position; each of said plurality of elongated frame members (16A, 16B, 16C, 16D) being attached at a first end (38) to one of said plurality of articulating joints (18A, 18B, 18C, 18D) and attached at a second end (40) to another one of said plurality of articulating joints (18A, 18B, 18C, 18D); wherein said plurality of elongated frame members (16A, 16B, 16C, 16D), are made of a ductile material that can be deformed plastically into a deformed shape and substantially retain the deformed shape and wherein said fabric structure (10) can be folded to a substantially flat configuration by rotating said plurality of articulating joints.
 2. The flexible frame of claim 1, wherein: each of said plurality of articulating joints (18A, 18B, 18C, 18D) comprises a first clevis (32) having a first rotation axis, a second clevis (34) having a second rotation axis, and a connecting link (36) extending between the first rotation axis and the second rotation axis.
 3. The flexible frame of claim 1, wherein: each of said plurality of articulating joints (18A, 18B, 18C, 18D) further includes an elongated clip (22) for securing said plurality of articulating joints to the fabric structure (10).
 4. The flexible frame of claim 1, wherein: said plurality of articulating joints (18A, 18B, 18C, 18D) comprises at least four articulating joints; and said plurality of elongated frame members (16A, 16B, 16C, 16D), comprises at least four elongated frame members, said plurality of elongated frame members (16A, 16B, 16C, 16D), and said plurality of articulating joints (18A, 18B, 18C, 18D) being arranged to form a closed loop.
 5. The flexible frame of claim 4, further comprising: a fabric structure (10) supported by the flexible frame (14).
 6. The flexible frame of claim 5, wherein: the fabric structure (10) comprises a hat.
 7. The flexible frame of claim 1, further comprising: a flexible sheath (38) enclosing each of said plurality of elongated frame members (16A, 16B, 16C, 16D), said flexible sheath acting to increase the effective diameter of each of said plurality of elongated frame members (16A, 16B, 16C, 16D), and to increase the bending radius of said plurality of elongated frame members (16A, 16B, 16C, 16D).
 8. The flexible frame of claim 7, wherein: said flexible sheath (30) comprises a hollow vinyl screen spline. 